Mixing valve assembly having an atomizing spray tip

ABSTRACT

A valve including a feed mechanism, a mixing element operably connected to the feed mechanism, wherein the feed mechanism delivers at least two fluids to the mixing element, the at least two fluids being mixed in the mixing element, and an air cap disposed proximate an outlet of the mixing element to atomize the mixed fluids exiting the outlet of the mixing element, is provided. Furthermore, an associated method is also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional application claiming the benefitof and priority to U.S. Provisional Application No. 62/330,606, filedMay 2, 2016, and entitled, “Mixing Valve Assembly Having an AtomizingSpray Tip.”

FIELD OF TECHNOLOGY

The following relates to a valve having an air cap and more specificallyto embodiments of a mixing valve assembly having an atomizing air capfor atomizing mixed fluids.

BACKGROUND

When applying adhesive or sealants to various surfaces, control of thespray of fluid is critical. The fluids may sometimes need to be reactedtogether in a mixer, wherein one or both of the fluids have a short potlife. In applications where fluid is sprayed onto a surface orsubstrate, the fluid(s) must be atomized. Atomizing a mixed fluidproximate an outlet can be known to sacrifice control of the spraypattern.

Thus, a need exists for an apparatus and method for metering two or moreproducts with short or long pot lives with selective control of thespray pattern.

SUMMARY

A first aspect relates generally to a valve comprising: a feed mechanismhaving at least two pumps, a mixing element operably connected to thefeed mechanism, wherein the feed mechanism delivers at least two fluidsto the mixing element, the at least two fluids being mixed in the mixingelement, and an air cap disposed proximate an outlet of the mixingelement to atomize the mixed fluids exiting the outlet of the mixingelement.

A second aspect relates generally to a valve comprising: a feedmechanism, the feed mechanism having a first pump and a second pump, thefirst pump configured to advance a first adhesive and the second pumpconfigured to advance a second adhesive, a fluid body affixed to thefeed mechanism, the fluid body receiving a portion of the first pump anda portion of the second pump, in a first end, wherein a first fluidpathway associated with the first pump and a second fluid pathwayassociated with the second pump, an attachment component, the attachmentcomponent affixed to a bottom surface of the fluid body, the attachmentcomponent cooperating with an end of a mixing element to removablyattach the mixing element to the fluid body, wherein the mixing elementmix the first adhesive and the second adhesive to form a mixed adhesive,a spray body, the spray body surrounding the mixing element, wherein thespray body includes a recessed surface having external threads, and aspray tip, the spray tip removably attached to the spray body.

A third aspect relates generally to a method comprising: providing avalve comprising a feed mechanism having at least two pumps, a mixingelement operably connected to the feed mechanism, wherein the feedmechanism delivers at least two fluids to the mixing element, the atleast two fluids being mixed in the mixing element, and an air capdisposed proximate an outlet of the mixing element, and atomizing themixed fluids exiting the outlet of the mixing element, such that adefined spray pattern is maintained as the mixed fluids are delivered toa substrate.

The foregoing and other features of construction and operation will bemore readily understood and fully appreciated from the followingdetailed disclosure, taken in conjunction with accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the embodiments will be described in detail, with reference tothe following figures, wherein like designations denote like members,wherein:

FIG. 1 depicts a perspective view of a first embodiment of a valve;

FIG. 2 depicts a front view of the first embodiment of the valve;

FIG. 3 depicts a side view of the first embodiment of the valve;

FIG. 4 depicts an assembly view of the first embodiment of the valve;

FIG. 5 depicts a cross-sectional view of the first embodiment of thevalve;

FIG. 6 depicts a front view of the first embodiment of the valve havinga remotely connected feed mechanism;

FIG. 7 depicts a front view of an embodiment of an air cap;

FIG. 8 depicts a cross-sectional view of the embodiment of the air cap;

FIG. 9 depicts an embodiment of a machine having a valve;

FIG. 10 depicts an embodiment of a valve attached to an end effector;

FIG. 11 depicts a perspective view of a second embodiment of a valve;

FIG. 12 depicts a front view of the second embodiment of the valve;

FIG. 13 depicts a side view of the second embodiment of the valve;

FIG. 14 depicts an assembly view of the second embodiment of the valve;

FIG. 15 depicts a cross-sectional view of the second embodiment of thevalve;

FIG. 16 depicts a front view of an alternative embodiment of a feedmechanism;

FIG. 17 depicts a side view of an alternative embodiment of the feedmechanism;

FIG. 18 depicts a cross-sectional view of an alternative embodiment ofthe feed mechanism;

FIG. 19 depicts a front view of the second embodiment of the valvehaving a remotely connected feed mechanism;

FIG. 20 depicts a front view of an embodiment of an air cap; and

FIG. 21 depicts a cross-sectional view of the embodiment of the air cap;

DETAILED DESCRIPTION

A detailed description of the hereinafter described embodiments of thedisclosed apparatus and method are presented herein by way ofexemplification and not limitation with reference to the Figures.Although certain embodiments are shown and described in detail, itshould be understood that various changes and modifications may be madewithout departing from the scope of the appended claims. The scope ofthe present disclosure will in no way be limited to the number ofconstituting components, the materials thereof, the shapes thereof, therelative arrangement thereof, etc., and are disclosed simply as anexample of embodiments of the present disclosure.

As a preface to the detailed description, it should be noted that, asused in this specification and the appended claims, the singular forms“a”, “an” and “the” include plural referents, unless the context clearlydictates otherwise.

Referring to the drawings, FIG. 1-5 depict an embodiment of a valve 100.Embodiments of valve 100 may be operably attached to an end effector.The end effector may be configured to be located within a machine orsystem having a frame, an X-axis actuator, a Y-axis actuator, and aZ-axis actuator. The machine housing or other component element(s)receiving the end effector may utilize a robotic platform to performautomated tasks with accuracy, precision, and repeatability. Forexample, the machine may be a Gantry robot having a plurality ofprincipal axes (Cartesian coordinates) controlling linear motion,wherein the horizontal member(s) may be supported at both ends. Themachine may also be any robotic manipulator such as a selectivecompliant assembly robot arm (SCARA) system, linear robot, multi-axisrobot arm system, and the like. However, an embodiment of the machinewill be described as utilizing a Gantry robot for exemplary purposes.The end effector may refer to any device(s) attached to a X, Y, Z orother axis of movement to perform a variety of tasks, such asdispensing, picking and placing, routing, and the like. For instance, anend effector is capable of rotation about the Z axis, and may move leftand right along the Y axis by sliding along the Y axis actuator, andmove back and forth along the X axis by sliding with the Y axis actuatoras it slides along the X axis actuator. Additionally, the end effectormay move up and down on the Z-axis by sliding along the Z-axis actuator.The X-axis actuator, the Y-axis actuator, and the Z-axis actuator may bea ball screw slide, linear motion slide, a linear actuator, and thelike. Moreover, the frame of the machine enclosing, housing, orotherwise receiving the end effector (and potentially other endeffectors) may provide a structure surrounding the components of themachine. The frame may allow for panels to be attached providing anenclosure for the machine. The panels attached to the frame may be acombination of both solid panels and see-through panels, such asPlexiglas®, glass, plastic, and the like, to allow operational viewing.

Embodiments of the valve 100 may be a device, an apparatus, valve,mixing valve, two-part spray head, dual-component spray valve, or systemthat is configured to deliver a fluid on a surface, edge, and/orperimeter of a substrate. Embodiments of the fluid delivered by thevalve 100 may be a reactive material(s), mixed reactive product, such asa two-part reactive product having a short pot life, such as a pot lifeless than 5 minutes. The fluid may be formed by mixing/reacting at leasttwo of a thermoplastic adhesive, a component adhesive, a reactiveadhesive, a mixed adhesive, or an optically clear adhesive, a reactiveproduct, or a substance having a short pot life, such as a pot life lessthan 5 minutes (a pot life longer than 5 minutes may also be used). Thefluid may be pumped, fed, delivered, or otherwise advanced towards anozzle for delivering onto a target separately and then mixed/reactedprior to exiting an outlet of the valve 100. Embodiments of valve 100may include progressive pumps with an integrated spray cap for selectiveapplication of reactive materials. For instance, embodiments of thevalve 100 may selectively coat a circuit board (e.g. coat some areas ofthe circuit board and not others) by spraying a reactive material, mixedby a mixing element, onto the target substrate, wherein the reactivematerial is atomized prior to exiting the nozzle. An integrated air capallows for a control of the atomized reactant material for selectiveapplications.

Moreover, embodiments of the valve 100 may include a feeding mechanism10, a mixing element 50, and an air cap 70, wherein reacted componentsmay be sprayed onto a substrate in a controllable manner.

Embodiments of two or more fluids may first be fed into a mixing element50 by a feeding mechanism 10. Embodiments of the feeding mechanism 10may be a fluid delivery system, a metering device, a pump system, andthe like. The feeding mechanism 10 may be any mechanism that can delivertwo or more fluids to an outlet. Embodiments of the feeding mechanism 10may be operably connected to an outlet of valve 100. In one embodiment,as shown in FIGS. 1-5, the feeding mechanism 10 may be directlyconnected to an outlet of the valve 100 via one or more structuralcomponents connected thereto. In other embodiments, such as shown inFIG.6, the feeding mechanism 10 may be remotely connected to the outletof the valve 100. For instance, the feeding mechanism 10 may be operablyconnected via one or more lines that deliver the fluid to one or morecomponents proximate the outlet of the valve 100. This may allow forflexibility of the valve 100, such as tilting, rotation, and othermovement.

Moreover, embodiments of the feed mechanism 10 may deliver two or morefluids through operation of one or more pumps 11 a, 11 b of a valve 100.Embodiments of the pumps may include one or more progressive cavitypumps 11 a, 11 b, which may combine to form a two-part valve head. Forexample, embodiments of the feeding mechanism 10 may include one or morepumps 11 a, 11 b, and an electrical port 12 a, 12 b associated with thepumps 11 a, 11 b, respectively. In one embodiment, the pumps 11 a, 11 bmay be in a side-by-side or parallel arrangement. In another embodiment,the pumps 11 a, 11 b may be in a V-shaped arrangement. The pumps 11 a,11 b may be a volumetric pump utilizing a progressive cavity principle,incorporating a machined auger-like rotor. Alternatively, the pumps maybe a gear pump, a piston pump, or other metering device.

In embodiments where the feed mechanism 10 is not remotely attached,embodiments of the feeding mechanism 10 may include a fluid body 15,wherein the fluid body 15 may be operably attached to the feedingmechanism 10 (e.g. via a plurality of fasteners 17). The fluid body 15may be configured to operably receive a second end 52 of a mixingelement 50. Embodiments of the fluid body 15 may be referred to as amanifold. Embodiments of the fluid body 15 of the feeding mechanism 10may include a first fluid path 15 a and a second fluid path 15 b forreceiving and accommodating a first and second fluid, which flows fromthe pumps 11 a, 11 b to the mixing element 50. Embodiments of the firstand second fluid path 15 a, 15 b may be a bore or similar opening in thefluid body 15 that, at one end is in fluid communication with a fluidsource for receiving a fluid, such as an adhesive, and at the other endis in fluid communication with the mixing element 50. In other words,one or more fluids may be drawn, forced, or otherwise fed from a fluidsource (e.g. via tube or hose connection to the source) through thefirst and/or second fluid path 15 a, 15 b to the second end 52 of themixing element 50 through operation of one or more pump, such as pumps11 a, 11 b. Further, embodiments of the fluid body 15 may include aconnector 16. The connector 16 may mate with the mixing element 50. Theconnector 16 may include two outlets for the pumped fluids, which can becombined in the mixer 50. The components of the valve head 100 may becomprised of metal, plastic, composite, or a combination thereof.

Referring still to FIGS. 1-5, embodiments of valve 100 may furtherinclude a mixing element 50. Embodiments of the mixing element 50 may beoperably connected to the feeding mechanism as shown in FIG. 5. In otherwords, the mixing element 50 may be located or otherwise disposedbetween the fluid body 15 of the feeding mechanism 10 and the spray tip70. Embodiments of the mixing element 50 may have a first end 51, asecond end 52, and an internal pathway 53 therebetween. Embodiments ofthe mixing element 50 may be a vessel or tube that is configured toreceive one or more types of fluids, such as two reactive adhesives at asecond end 52 from the feeding mechanism 10. For example, a first fluidmay enter the mixing element 50 from the first fluid path 15 a and asecond fluid may enter the mixing element 50 from the second fluid path15 b for mixing and/or reaction with one another. The first fluid andthe second fluid entering the mixing element 50 from the feedingmechanism 10 may be different fluids, similar fluids, the same fluids,and combination of fluids entering the mixing element 50 for furtherreaction and mixing. Embodiments of the mixing element 50 may be astatic or dynamic mixer, and may be rigid or flexible. Once within themixing element 50, the reactive adhesives may mix or otherwise reactwith each other and travel through the internal pathway 53 of the mixingelement 50. The adhesives contained within the mixing element 50 maythen exit the mixing element 50 through an opening at the first end 51,wherein the mixed fluid is atomized and delivered to a substrate withprecision and accuracy, as described in greater detail infra.

Embodiments of valve 100 may further include a spray body 40.Embodiments of spray body 40 may include an axial opening 45therethrough, which may receive the mixing element 50, and alsopotentially a spacer 80. The axial opening 45 of the spray body 40 mayextend from a first end 41 to a second end 42, such that the opening 45extends entirely through the spray body 40. Further, embodiments ofopening 45 of the spray body 40 may have a reduced diameter startingfrom an internal lip 46 and extending to the first end 41 of the spraybody 40. The spray body 40 may be operably attached to the fluid body 15of the valve 100 via one or more fasteners 48. The fasteners 48 may passthrough openings on one more flanges 49 a, 49 b of the spray body 40.Moreover, embodiments of the spray body 40 may have external threadsproximate the first end 41 for mating with a collar 90. Embodiments ofthe collar 90, or retaining ring, may secure engagement between thespray body 40 and the air cap 70.

Additionally, embodiments of the valve 100 may further include anattachment plate 60. Embodiments of the attachment plate 60 may beconfigured to securably removable attach the mixing element 50 to thevalve 100. For instance, embodiments of the attachment plate 60 may befastened to a bottom surface of the fluid body 15 at one side of theattachment plate 60. The other side of the attachment plate 60 may facethe outlet end 1 of the valve 100. The attachment plate 60, beingfastened to the fluid body 15, may receive the second end 52 of themixing element 50 for removable attachment thereto. An irregular shapedopening of the attachment plate 60 matingly corresponds to structure onthe second end 52 of the mixing element 50, wherein the attachment plate60 may function as a collar for the mixing element 50. Thus, the mixingelement 50 may be removably attached to the attachment plate 60 and theconnector 16 of the fluid body 15.

Embodiments of the valve 100 may also include a spacer 80. Embodimentsof the spacer 80 may be a cylindrical member having an axial openingtherethrough. The spacer 80 may be disposed around the mixing element50, wherein a portion of the tube of the mixing element 50 is receivedwithin the axial opening of the spacer 80. Embodiments of the spacer 80may be disposed within an interior of the air cap 70. Further,embodiments of the spacer 80 may stabilize a portion of the mixingelement 50 disposed within the air cap 70.

With continued reference to FIGS. 1-5, and additional reference to FIGS.7-8, embodiments of the valve 100 may also include an air cap 70.Embodiments of air cap 70 may be a spray tip, an atomizer, an atomizingtip, an air tip, and the like. Embodiments of the air cap 70 may includea first end 71 and a second end 72, a collar 73, a tapered inlet 74, avertical extension 76, and a lower opening 77. Embodiments of the collar73 may include external threads to threadably engage threads of thecollar 90. Thus, to remove the air cap 70, a user may unthread thecollar 90, which allows for easy access to the mixing element 50 fordisposal and replacement. The lower opening 77 in the atomizing air cap70 is where the fluid material leaves the atomizing air cap 70 in anatomized state and is directed toward a substrate surface. FIG. 8 is across-sectional side view of the atomizing air cap 70 of FIG. 7. Aconverging inlet surface 78 may be included in the tapered inlet 74. Theconverging inlet surface 78 may gather compressed air entering theatomizing air cap 70 from air passages located in the spray body 40. Theair cap 70 may include a fluted inner surface 79 for generating laminarjets of compressed air.

Compressed air or a gas may be introduced into the valve 100 via one ormore inlet ports on the spray body 40. The compressed air or gas flowsthrough the air cap 70 to atomize the fluid exiting the mixing element50. For example, the compressed air may travel in a laminar flow throughthe air cap and when exiting, may act upon the fluid exiting the mixingelement 50 to atomize the fluid, yet keeping a defined round (orcorresponding shape of the air cap 70) spray pattern to impinge onand/or coat a substrate. The interior geometry and structure of the aircap 70 in combination with the compressed air or gas provides a cleanspray pattern for selective coating applications. For example, the spraypattern may be a fine, circular pattern with widths ranging from 0.125″to 0.5″.

In some embodiments, the mixing element 50 may be disposable while theair cap 70 is reusable. A reusable air cap 70 may be comprised of metal,such as stainless steel. In other embodiments, the mixing element 50 maybe disposable and the air cap 70 may also be disposable. A disposableair cap 70 may be comprised of a low-cost material, such as plastics,composites, aluminum, and the like. The air cap 70 may be manufacturedin a variety of methods known to those skilled in the art, including 3Dprinting methods.

Referring still to the drawings, FIGS. 9-19 depict an embodiment ofvalve 200. Embodiments of valve 200 may include the same orsubstantially the same structural or functional aspects of valve 100.Embodiments of valve 200 may include an alternative connection mechanismfor operably securing an atomizing tip to a mixing valve.

Specifically, embodiments of valve 200 may be operably attached to anend effector 4. The end effector 4 may be configured to be locatedwithin a machine 6 or system having a frame, an X-axis actuator, aY-axis actuator, and a Z-axis actuator, as shown in FIGS. 9-10. Themachine housing 6 or other component element(s) receiving the endeffector 4 may utilize a robotic platform to perform automated taskswith accuracy, precision, and repeatability. For example, the machinemay be a Gantry robot having three principal axes (Cartesiancoordinates) controlling linear motion, wherein the horizontal member(s)may be supported at both ends. The machine 6 may also be any roboticmanipulator such as a selective compliant assembly robot arm (SCARA)system, linear robot, multi-axis robot arm system, and the like.However, an embodiment of the machine 6 will be described as utilizing aGantry robot for exemplary purposes. The end effector 4 may refer to anydevice(s) attached to a X, Y, Z or other axis of movement to perform avariety of tasks, such as dispensing, picking and placing, routing, andthe like. For instance, an end effector is capable of rotation about theZ axis, and may move left and right along the Y axis by sliding alongthe Y axis actuator, and move back and forth along the X axis by slidingwith the Y axis actuator as it slides along the X axis actuator.Additionally, the end effector 4 may move up and down on the Z-axis bysliding along the Z-axis actuator. The X-axis actuator, the Y-axisactuator, and the Z-axis actuator may be a ball screw slide, linearmotion slide, a linear actuator, and the like. Moreover, the frame ofthe machine 6 enclosing, housing, or otherwise receiving the endeffector 4 (and potentially other end effectors) may provide a structuresurrounding the components of the machine 6. The frame may allow forpanels to be attached providing an enclosure for the machine. The panelsattached to the frame may be a combination of both solid panels andsee-through panels, such as Plexiglas®, glass, plastic, and the like, toallow operational viewing.

Embodiments of the valve 200 may be a device, an apparatus, a valve, amixing valve, or system that is configured to dispense a fluid on asurface, edge, and/or perimeter of a substrate for operable coating ofone or more surfaces or substrates, such as a circuit board, flexcircuit, and the like. Embodiments of the fluid delivered by the valve200 may be a reactant material(s), mixed reactive product, such as atwo-part reactive product an adhesive, having a short pot life, such asa pot life less than 5 minutes. The fluid may be formed bymixing/reacting at least two of a thermoplastic adhesive, a componentadhesive, a reactive adhesive, a mixed adhesive, or an optically clearadhesive, a reactive product, or a substance having a short pot life,such as a pot life less than 5 minutes (a pot life longer than 5 minutesmay also be used). The fluid may be pumped, fed, delivered, or otherwiseadvanced towards a nozzle for delivering onto a target separately andthen mixed/reacted prior to exiting the valve 200. Embodiments of valve200 may include progressive pumps with an integrated spray cap forselective application of reactive materials. For instance, embodimentsof the valve 200 may selectively coat a circuit board (e.g. coat someareas of the circuit board and not others) by spraying a reactivematerial, mixed by a mixing element, onto the target substrate, whereinthe reactive material is atomized prior to exiting the nozzle. Anintegrated air cap allows for a control of the atomized reactantmaterial for selective applications.

Moreover, embodiments of the valve 200 may include a feeding mechanism210, a mixing element 250, and an air cap 270, wherein reacted adhesivesmay be sprayed onto a substrate in a controllable manner.

Embodiments of two or more fluids may first be fed into a mixing element250 by a feeding mechanism 210. Embodiments of the feeding mechanism 210may be a fluid delivery system, a metering device, a pump system, andthe like. The feedings mechanism 210 may be any mechanism that candeliver two or more fluids to an outlet. Embodiments of the feedingmechanism 210 may be operably connected to an outlet of valve 100. Insome embodiments, as shown in FIGS. 9-17, the feeding mechanism 210 maybe directly connected to an outlet of the valve 200 via one or morestructural components connected thereto. FIGS. 11-15 depict a feedingmechanism 210 including at least two pumps, metering devices, and thelike. FIG. 16-18 depict an embodiment of a feeding mechanism 210 thatdoes not include pumps, but includes a precise on/off control of theflow of the fluids delivered to the mixing element. For instance, theembodiments of the feed mechanism 210 shown in FIGS. 16-18 may include apneumatic on/off flow control means including an inlet 213 for air orother gas to be introduced for closing flow of fluid, an inlet 214 forintroducing air or other gas for opening a flow of fluid, a first fluidpath 215 a, and a second fluid path 215 b. In other embodiments, such asshown in FIG.19, the feeding mechanism 210 may be remotely connected tothe outlet of the valve 200. For instance, the feeding mechanism 210 maybe operably connected via one or more lines that deliver the fluid toone or more components proximate the outlet of the valve 200. This mayallow for flexibility of the valve 200, such as tilting and othermovement.

Moreover, embodiments of the feed mechanism 210 may deliver two or morefluids through operation of one or more pumps 211 a, 211 b of a valve200, or other flow control means. Embodiments of the pumps may includeone or more progressive cavity pumps 211 a, 211 b, which may combine toform a two-part valve head. For example, embodiments of the feedingmechanism 210 may include one or more pumps 211 a, 211 b, and anelectrical port 212 a, 212 b associated with the pumps 211 a, 211 b,respectively. In one embodiment, the pumps 211 a, 211 b may be in aside-by-side or parallel arrangement. In another embodiment, the pumps211 a, 211 b may be in a V-shaped arrangement. The pumps 211 a, 211 bmay be a volumetric pump utilizing a progressive cavity principle,incorporating a machined auger-like rotor. Alternatively, the pumps maybe a gear pump, a piston pump, or other metering device.

Moreover, in embodiments where the feed mechanism 210 is not remotelyattached, embodiments of the feeding mechanism 210 may include a fluidbody 215, wherein the fluid body 215 may be operably attached to thefeeding mechanism 210 (e.g. via a plurality of fasteners 217). The fluidbody 215 may be configured to operably receive a second end 252 of amixing element 250. Embodiments of the fluid body 215 may be referred toas a manifold. Embodiments of the fluid body 215 of the feedingmechanism 210 may include a first fluid path 215 a and a second fluidpath 215 b for receiving and accommodating a first and second fluid,which flows from the pumps 211 a, 211 b to the mixing element 250.Embodiments of the first and second fluid path 215 a, 215 b may be abore or similar opening in the fluid body 215 that, at one end is influid communication with a fluid source for receiving a fluid, such asan adhesive, and at the other end is in fluid communication with themixing element 250. In other words, one or more fluids may be drawn,forced, or otherwise fed from a fluid source (e.g. via tube or hoseconnection to the source) through the first and/or second fluid path 215a, 215 b to the second end 252 of the mixing element 250 throughoperation of one or more pump, such as pumps 211 a, 211 b. Further,embodiments of the fluid body 215 may include a connector 216. Theconnector 216 may mate with the mixing element 250. The connector 216may include two outlets for the pumped fluids, which can be combined inthe mixer 250. The components of the valve head 200 may be comprised ofmetal, plastic, composite, or a combination thereof.

Referring still to FIGS. 9-19, embodiments of valve 200 may furtherinclude a mixing element 250. Embodiments of the mixing element 250 maybe operably connected to the feeding mechanism as shown in FIG. 15. Inother words, the mixing element 250 may located or otherwise disposedbetween the fluid body 215 of the feeding mechanism 210 and the spraytip 270. Embodiments of the mixing element 250 may have a first end 251,a second end 252, and an internal pathway 253 therebetween. Embodimentsof the mixing element 250 may be a vessel or tube that is configured toreceive one or more types of fluids, such as two reactive adhesives at asecond end 252 from the feeding mechanism 210. For example, a firstfluid may enter the mixing element 250 from the first fluid path 215 aand a second fluid may enter the mixing element 250 from the secondfluid path 215 b for mixing and/or reaction with one another. The firstfluid and the second fluid entering the mixing element 250 from thefeeding mechanism 210 may be different fluids, similar fluids, the samefluids, and combination of fluids entering the mixing element 250 forfurther reaction and mixing. Embodiments of the mixing element 250 maybe a static or dynamic mixer, and may be rigid or flexible. Once withinthe mixing element 250, the reactive adhesives may mix or otherwisereact with each other and travel through the internal pathway 253 of themixing element 250. The adhesives contained within the mixing element250 may then exit the mixing element 250 through an opening at the firstend 251, wherein the mixed fluid is atomized and delivered to asubstrate with precision and accuracy, as described in greater detailinfra.

Embodiments of the valve 200 may include an attachment component 260.Embodiments of the attachment component 260 may be configured tosecurably removable attach the mixing element 250 to the valve 200. Forinstance, embodiments of the attachment component 260 may be fastened toa bottom surface of the fluid body 215 at one side of the attachmentcomponent 260 via one or more fasteners 264. The other side of theattachment component 260 may face the outlet end 201 of the valve 200.The attachment component 260, being fastened to the fluid body 215, mayreceive the second end 252 of the mixing element 250 for removableattachment thereto. An irregular shaped opening of the attachmentcomponent 60 may matingly correspond to structure on the second end 252of the mixing element 250, wherein the attachment component 260 mayfunction as a collar for the mixing element 250. Thus, the mixingelement 250 may be removably attached to the attachment component 260and the connector 216 of the fluid body 215. An exterior surface of theattachment component 260, or a portion thereof, may include externalthreads for threadably mating with a retaining ring 290 to secure thespray body 240 to the valve 200.

Embodiments of valve 200 may further include a spray body 240.Embodiments of spray body 240 may include an axial opening 245therethrough, which may receive the mixing element 250, and alsopotentially a spacer 280. The axial opening 45 of the spray body 40 mayextend from a first end 241 to a second end 242, such that the opening245 extends entirely through the spray body 240. Further, embodiments ofopening 245 of the spray body 240 may have an internal radial flange 246that extends radial inward a distance from an interior surface of thespray body 240. The internal radial flange 246 may engage the mixingelement 250 disposed within the spray body 240. Embodiments of theinternal radial flange 246 may include a notch 247 on a side of theflange 246 that faces the first end 241 of the spray body 240. The notch247 may receive an end of the spacer 280 in an assembled configuration,as shown in FIG. 12. Moreover, embodiments of the spray body 240 mayinclude an external flange 243 proximate, or at the second end 242 ofthe spray body 240. The external flange 243 may include threads forthreadably mating with the retaining ring 90. The first end 241 of thespray body 240 may include a recessed surface 244, wherein the recessedsurface 244 or a portion thereof includes external threads forthreadably mating with a collar 295 that threadably secures the air cap270 to the valve 200.

Embodiments of the valve 200 may also include a spacer 280. Embodimentsof the spacer 280 may be a cylindrical member having an axial openingtherethrough. The spacer 280 may be disposed around the mixing element250, wherein a portion of the tube of the mixing element 250 is receivedwithin the axial opening of the spacer 280. Embodiments of the spacer280 may be disposed within an interior of the air cap 270, wherein oneend of the spacer 80 may reside within notch 247 of the spray body 240in an assembled configuration. Further, embodiments of the spacer 280may stabilize a portion of the mixing element 250 disposed within theair cap 270.

With continued reference to FIGS. 9-19, and additional reference toFIGS. 20-21, embodiments of the valve 200 may also include an air cap270. Embodiments of air cap 270 may be a spray tip, an atomizer, anatomizing tip, an air tip, and the like. Embodiments of the air cap 270may include a first end 271 and a second end 272, a collar 273, atapered inlet 274, a vertical extension 276, and a lower opening 277.Embodiments of the collar 273 of the spray cap 270 may include externalthreads to threadably engage threaded surface 296 of the collar 295.Thus, to remover the air cap 270, a user may unthread the collar 295,which provides easy access to the mixing element 250 for disposal andreplacement. The additional retainer ring 290 may also be unthreaded toallow for removal of the spray body 240 for further access to the mixingelement 250. The lower opening 277 in the atomizing air cap 270 is wherethe fluid material leaves the atomizing air cap 270 in an atomized stateand is directed toward a substrate surface. FIG. 18 is a cross-sectionalside view of the atomizing air cap 270 of FIG. 15. A converging inletsurface 278 may be included in the tapered inlet 274. The converginginlet surface 278 may gather compressed air or other gas entering theatomizing air cap 270 from air passages located in the spray body 240.The air cap 270 may include a fluted inner surface 279 for generatinglaminar jets of compressed air or other gas.

Compressed air may be introduced into the valve 200 via one or moreinlet ports on the spray body 240. The compressed air flows through theair cap 270 to atomize the fluid exiting the mixing element 250. Forexample, the compressed air may travel in a laminar flow through the aircap and when exiting, may act upon the fluid exiting the mixing element250 to atomize the fluid, yet keeping a defined round spray pattern toimpinge on and/or coat a substrate. The interior geometry and structureof the air cap 270 in combination with the compressed air provides aclean spray pattern for selective application. For example, the spraypattern may be a fine, circular pattern with widths ranging from 0.125″to 0.5″.

In some embodiments, the mixing element 50 may be disposable while theair cap 70 is reusable. A reusable air cap 70 may be comprised of metal,such as stainless steel. In other embodiments, the mixing element 50 maybe disposable and the air cap 70 may also be disposable. A disposableair cap 70 may be comprised of a low-cost material, such as plastics,composites, aluminum, and the like. The air cap 70 may be manufacturedin a variety of methods known to those skilled in the art, including 3Dprinting methods.

Referring to FIGS. 1-21, a method of atomizing a mixed fluid, such astwo or more adhesives may include the steps of providing a valve 100,200 having a mixing element 50, 250 and an air cap 50, 250, whereincompressed air is supplied to the valve 100, 200 for atomizing the mixedfluid that exits the mixing element 50, 250.

While this disclosure has been described in conjunction with thespecific embodiments outlined above, it is evident that manyalternatives, modifications and variations will be apparent to thoseskilled in the art. Accordingly, the preferred embodiments of thepresent disclosure as set forth above are intended to be illustrative,not limiting. Various changes may be made without departing from thespirit and scope of the invention, as required by the following claims.The claims provide the scope of the coverage of the invention and shouldnot be limited to the specific examples provided herein.

What is claimed is:
 1. A valve comprising: a feed mechanism; a mixingelement operably connected to the feed mechanism, wherein the feedmechanism delivers at least two fluids to the mixing element, the atleast two fluids being mixed in the mixing element; and an air capdisposed proximate an outlet of the mixing element to atomize the mixedfluids exiting the outlet of the mixing element.
 2. The valve of claim1, wherein the air cap is threadably attached.
 3. The valve of claim 1,further comprising a fluid body fastened to the feeding mechanism, thefluid body configured to receive an end of the mixing element, andhaving a first fluid flow path and a second fluid flow path.
 4. Thevalve of claim 3, further comprising a spray body, the spray body beingfastened to the fluid body, wherein the spray body surrounds the mixingelement.
 5. The valve of claim 4, further comprising a collar, thecollar securing engagement between the air cap and the spray body. 6.The valve of claim 1, wherein compressed air is introduced to the aircap to atomize the mixed fluids.
 7. The valve of claim 1, wherein thevalve is attached to an end effector located within a gantry robotmachine for conformally coating a substrate.
 8. A valve comprising: afeed mechanism, the feed mechanism having a first pump and a secondpump, the first pump configured to advance a first adhesive and thesecond pump configured to advance a second adhesive; a fluid bodyaffixed to the feed mechanism, the fluid body receiving a portion of thefirst pump and a portion of the second pump, in a first end, wherein afirst fluid pathway associated with the first pump and a second fluidpathway associated with the second pump; an attachment component, theattachment component affixed to a bottom surface of the fluid body, theattachment component cooperating with an end of a mixing element toremovably attach the mixing element to the fluid body, wherein themixing element mix the first adhesive and the second adhesive to form amixed adhesive; a spray body, the spray body surrounding the mixingelement, wherein the spray body includes a recessed surface havingexternal threads; and a spray tip, the spray tip removably attached tothe spray body.
 9. The valve of claim 8, further comprising a collar,the collar retaining the spray tip to the spray body.
 10. The valve ofclaim 8, wherein the attachment component includes an irregular shapedopening that mating corresponds to structure defining the end of themixing element.
 11. The valve of claim 8, wherein the mixed adhesiveleaves the spray tip in an atomized state and is directed toward asubstrate surface.
 12. The valve of claim 8, wherein compressed air isintroduced into the valve via one or more air inlet ports on the spraytip.
 13. The valve of claim 8, wherein the spray tip is disposable, 14.The valve of claim 8, wherein the spray tip is comprised of a plasticmaterial.
 15. The valve of claim 8, further comprising a spacer tostabilize the mixing element.
 16. The valve of claim 1, wherein thevalve is attached to an end effector located within a gantry robotmachine for conformally coating a substrate.
 17. A method comprising:providing a valve comprising a feed mechanism having at least two pumps,a mixing element operably connected to the feed mechanism, wherein thefeed mechanism delivers at least two fluids to the mixing element, theat least two fluids being mixed in the mixing element, and an air capdisposed proximate an outlet of the mixing element; and atomizing themixed fluids exiting the outlet of the mixing element, such that adefined spray pattern is maintained as the mixed fluids are delivered toa substrate.
 18. The method of claim 17, wherein the air cap isthreadably attached to the valve.
 19. The method of claim 17, whereinthe valve is attached to an end effector located within a gantry robotmachine for conformally coating a substrate.
 20. The method of claim 17,wherein compressed air is introduced to the air cap to atomize the mixedfluids.